ECE 477 Digital Systems Senior Design Project Spring 2008

Homework 5: Theory of Operation and Hardware Design Narrative

Due: Friday, February 15, at NOON
Team Code Name: The Two Wheel Deal Group No !"
Team #em$er Completing This Homework: Greg %akins
e&mail 'ddress of Team #em$er: geakins ( purdueedu
NOTE: This is the second in a series of four design component homeor! assignments"
each of hich is to #e comp$eted #% one team mem#er& The comp$eted homeor! i$$ count
for 20' of the indi(idua$ component of the team mem#er)s grade& The #od% of the report
shou$d #e *+, pages" not inc$uding this co(er page" references" attachments or appendices&
%valuation:
)CO*% -ESC./0T/ON
10
Excellent among the best papers submitted for this assignment. Very few
corrections needed for version submitted in Final Report.
2
Very good all reuirements aptly met. !inor additions"corrections needed for
version submitted in Final Report.
8
Good all reuirements considered and addressed. Several noteworthy
additions"corrections needed for version submitted in Final Report.
7
Average all reuirements basically met# but some revisions in content should be
made for the version submitted in the Final Report.
3
Marginal all reuirements met at a nominal level. Significant revisions in
content should be made for the version submitted in the Final Report.
4
Belo t!e "a##ing t!re#!old major revisions reuired to meet report
reuirements at a nominal level. $evi#e and re#ub%it&
4 Resubmissions are due within one ee' of the date of return# and will be awarded a score of
$%& provided all report reuirements have been met at a nominal level.
Comments:
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ECE 477 Digital Systems Senior Design Project Spring 2008
!+ ,ntrodu-tion
-ue to its duties as an upright #a$ancing transportation de(ice" The To 5hee$ -ea$
re6uires a uni6ue mi7ture of high sensiti(it% and high poer circuitr% in order to proper$%
#a$ance and transport a person& On the sensor side" it needs a precise sensor and microcontro$$er
circuit to fine tune the demanded motor tor6ue #ased on readings from mu$tip$e sensors and user
inputs& On the poer side" this (ehic$e needs high current motor contro$$ers to #ridge the gap
#eteen the microcontro$$er and the poerfu$ -C motors on #oard" a$ong ith high capacit%
#atteries to supp$% the re6uired current&
"+ Theory of Operation
.ower )upply
8$$ of the poer for The To 5hee$ -ea$ comes from a pair of 129 sea$ed $ead acid
hee$ chair #atteries ired in series to pro(ide the circuit ith 249& The #atteries are used to
supp$% current primari$% to the motor contro$$ers" hich direct the current through the N0C+T74
motors& The 249 from the #atteries is stepped don to 129 using a $inear (o$tage regu$ator&
Though this is an inefficient means of regu$ating a $arge (o$tage difference" the simp$icit% of the
circuit and the resi$ience to (o$tage ripp$e caused #% the motor contro$$ers far outeigh the
additiona$ current consumption hich" hen compared to the current consumption of the motors"
is miniscu$e& The 129 from these regu$ators is used for poering the :ET dri(ers on each motor
contro$$er& The (o$tage is again stepped don from 129 to ,9 using a $inear (o$tage regu$ator to
ensure that the microcontro$$er and sensor circuit recei(e a sta#$e (o$tage& The constanc% of the
,9 $ine is critica$ for the proper interaction of the sensors and the microcontro$$er& :$uctuations
in the input (o$tage of the sensors i$$ resu$t in undesira#$e changes on the output of the sensors&
The microcontro$$er" sensors" 0;-s" ;C-" and (arious other support de(ices are poered #% the
,9 regu$ator& 8$$ components outside of the motor contro$$ers are ,9 de(ices to simp$if% the
poer supp$% circuit" as e$$ as e$iminate an% need for $e(e$ trans$ators or amp$ification
hardare&
#i-ro-ontroller
The 8Tmega*2 microcontro$$er interfaces to a$$ of the ma<or components of the (ehic$e&
/t runs off of an e7terna$ cr%sta$ osci$$ator at the microcontro$$er)s ma7imum c$oc! speed of 13
=>? to ma7imi?e the a(ai$a#$e computing poer& /t uses the 8T- modu$e to read an ana$og
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ECE 477 Digital Systems Senior Design Project Spring 2008
signa$ from the acce$erometers" the g%roscopic angu$ar rate sensor" the steering <o%stic!" and the
#atter% $e(e$ meter& @ased on the incoming data" it computes the dut% c%c$e of to outgoing
05= signa$s that are used to command tor6ue from the motors& 8t the same time" the
microcontro$$er interfaces to an ;C- screen to gi(e the dri(er feed#ac! on the state of the
(ehic$e&
)ensors
8 dua$ a7is acce$erometer and a sing$e a7is angu$ar rate sensor are used to determine the
angu$ar position and angu$ar (e$ocit% of the (ehic$e a#out its dri(e a7is& @oth sensors ha(e
ana$og outputs that are fed direct$% to the microcontro$$er)s 8T- channe$s& @oth sensors ha(e
interna$ signa$ conditioning circuitr%" reducing or e$iminating the need for fi$tering circuitr%&
0h%sica$ orientation of each sensor is e7treme$% important for o#taining the correct information
on the (ehic$e)s mo(ements A1BA2B& To faci$itate proper mounting of the sensors ithout
resorting to e7traneous mounting of each sensor" the entire microcontro$$er and sensor 0C@ is
mounted perpendicu$ar to the ground a$ong the center$ine of the (ehic$e&
@atter% $e(e$ monitoring is performed #% using a simp$e high resistance (o$tage di(ider
connected direct$% to the #atter%& The 249 #atter% (o$tage is di(ided don to ,9 to a$$o the
8T- con(erters to read changes in the (o$tage of the #atter%& Cnoing the state of the #atter%)s
charge i$$ a$$o the contro$$er to compensate for a $o #atter% #% increasing the dut% c%c$e of
the 05= signa$ going to the motor contro$$ers" !eeping the (ehic$e)s performance constant o(er
the $ife of the #atter%&
8n infrared rider detection sitch in the hand$e#ar of the (ehic$e $ets the s%stem !no
hen the rider has dismounted Deither i$$ing$% or uni$$ing$%E& ;ogic in the softare a$gorithm
i$$ insert a de$a% #efore an% action is ta!en upon detecting a missing rider& This a$$os the rider
to temporari$% remo(e their hands from the hand$e#ars if need #e ithout the (ehic$e coming to
an undesired ha$t&
#otor Controller
Each motor contro$$er is contro$$ed using a 05= signa$ from the microcontro$$er running
at a fre6uenc% of appro7imate$% 2 !>?& Fsing this $o fre6uenc% signa$ can cause an audi#$e
hine from the motors" #ut it increases the poer hand$ing of the circuit #% reducing the $osses
generated #% sitching the :ETs& The 05= signa$ is not fed direct$% to the =OS:ETs" #ut
instead it is fed to a :ET dri(er that ta!es care of man% of the important detai$s of dri(ing an >+
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ECE 477 Digital Systems Senior Design Project Spring 2008
#ridge" such as app$%ing the right (o$tages to the =OS:ET gates and inserting a s$ight de$a%
#efore sitching from forard and re(erse to pre(ent a circuit destro%ing shoot+through
situation&
The :ET contro$$er contro$s a simp$e =OS:ET >+#ridge& Each $eg of the #ridge ho$ds *
=OS:ETs rated at 1008 continuous$%& This gi(es each one of The To 5hee$ -ea$)s motor
contro$$ers a theoretica$ current capacit% of a#out *00 amps" though gi(en the passi(e coo$ing
s%stem" 1,08 is a more rea$istic (a$ue A*B&
E(en though the :ET dri(ers he$p pre(ent shoot+through #% inserting a s$ight de$a%
#efore changing directions A4B" specia$ circuitr% has #een added to the >+#ridges to compensate
for the $arge =OS:ETs used in this design& The $arge gate capacitances Don the order of a fe
G:E cause a si?a#$e de$a% in the turn+off time of each :ET" and if the opposing set of :ETs turn
on #efore the first set turns off" shoot through i$$ occur& .esistors ha(e #een added in series
ith the gate of each transistor to s$o don the turn on time" and a Schott!% diode ired in
para$$e$ ith the resistor aid in speeding up the turn off time of each :ET #% pu$$ing the charge
off of the transistor)s gate&
Each motor contro$$er re6uires that the incoming 05= signa$ #e sitched #eteen to
separate pins to sitch the motor contro$$er #eteen forard and re(erse& Since the
microcontro$$er on$% has enough 05= channe$s to supp$% 1 05= signa$ to each motor
contro$$er" additiona$ $ogic must #e added to a$$o for a sing$e 05= signa$ to command #oth
forard and re(erse& Though this $ogic can #e imp$emented using a fe discreet $ogic gates" a
sing$e 0;- is used to simp$if% this circuit and a$$o for future e7pansion&
The rapid sitching of high current inducti(e $oads ma!es the motor contro$$er an
e$ectrica$$% chaotic part of the circuit& To pro(ide a measure of safet% to the microcontro$$er and
$ogic circuits" the motor contro$$er circuits are separated from the microcontro$$er circuit #%
running each 05= signa$ through an optica$ iso$ator&
Human ,nterfa-e
8n ;C- screen is used to pro(ide the user ith (ehic$e information such as appro7imate
(ehic$e speed and #atter% $ife& The microcontro$$er interfaces to the ;C- screen direct$% using a
para$$e$ interface& Steering of the (ehic$e is imp$emented #% reading the (o$tage output from a
(aria#$e resistance <o%stic! circuit& This (a$ue is sent direct$% to an 8T- channe$ on the
microcontro$$er&
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ECE 477 Digital Systems Senior Design Project Spring 2008
/+ Hardware Design Narrative
The 05= modu$e of the 8Tmega*2 is used to send a tor6ue demand to the motors& The
microcontro$$er has on$% to 13+#it 05= outputs" and #oth i$$ #e uti$i?ed& These outputs
correspond to pins OC18 and OC1@& Henera$ /IO pins 0-0 and 0-1 ha(e #een chosen to
contro$ the direction of the motors primari$% due to their c$ose pro7imit% to the 05= output
pins&
The 8T- modu$e is used e7tensi(e$% for reading the (a$ues coming from the sensors& 8$$ of
the sensors ha(e a 0+,9 output range" so the% can #e direct$% connected to the 8T- pins& The
dua$ a7is acce$erometer)s to outputs uses 8T- pins 081 and 082" the output of the angu$ar rate
sensor uses 08*" the 2&,9 reference (o$tage of the angu$ar rate sensor uses 084" the steering
<o%stic! uses 08," and the #atter% $e(e$ circuit is connected to 080&
The ;C- screen i$$ ta!e up the most /IO pins& 5hi$e the para$$e$ interface of the ;C-
cou$d #e using the S0/ and a shift register to sa(e microcontro$$er pins" a high num#er of free /IO
pins ma!e this an unnecessar% addition to the circuit& The ;C- screen re6uires 10 pins to
operate& The 8 data #its i$$ use pins 0C0+0C7& These pins are contro$$ed interna$$% #% a sing$e
data register& 0utting a$$ of the ;C- data pins together simp$ifies the softare a$gorithm for
riting data to the ;C-& The screen needs a register se$ect D.SE and a c$oc! signa$ DEE as e$$"
and these are assigned to pins 087 and 0-7 respecti(e$%& 0$acing these signa$s in c$ose
pro7imit% simp$ifies the ph%sica$ routing on the 0C@&
The signa$s from the passenger detection sensors i$$ #e reduced to a sing$e signa$ #% using
a 0;-& That signa$ i$$ #e read #% pin 083 on the microcontro$$er& 8 summar% of the
microcontro$$er pin assignments can #e found in Ta#$e *&1&
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ECE 477 Digital Systems Senior Design Project Spring 2008
)ignal .in Name .in Num$er
05= =otor Contro$$er Tor6ue -emand OC18" OC1@ 12" 18
=otor Contro$$er -irection Contro$ 0-0" 0-1 14" 1,
2+a7is 8cce$erometer 081" 082 *2" *8
8ngu$ar .ate Sensor 08*"084 *7"*3
Steering Jo%stic! 08, *,
@atter% ;e(e$ =onitor 080 40
;C- -ata 0C0+0C7 22+22
;C- .egister Se$ect D.SE 087 **
;C- C$oc! DEE 0-7 21
0assenger -etection 083 *4
Ta$le /! K Summar% of =icrocontro$$er 0in Fsage
0+ )ummary
The To 5hee$ -ea$)s circuitr% has #een carefu$$% designed around creating a circuit that is
#oth sensiti(e enough to proper$% detect and react to sma$$ changes in the (ehic$e)s d%namics" %et
poerfu$ enough to mo(e a person& The $ead acid #atteries supp$% amp$e current to the motors"
hi$e the $inear (o$tage regu$ators pro(ide a sta#$e poer supp$% to the (o$tage sensiti(e digita$
components& 8 microcontro$$er sits at the center of the design" interfacing direct$% to a$$ of the
sensors and user inputs hi$e interfacing through iso$ation circuits to the motor contro$$ers to
pre(ent damage to the de$icate circuitr% surrounding the microcontro$$er& The end resu$t is
simp$e %et effecti(e rea$i?ation of a circuit that performs a$$ of the ca$cu$ations" sensing" and
poer de$i(er% re6uired for The To 5hee$ -ea$&
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ECE 477 Digital Systems Senior Design Project Spring 2008
1ist of *eferen-es
A1B 8na$og -e(ices" 8na$og -e(ices 8-L;10*I8-L;20* -ata Sheet" AOn$ine -ocumentB"
Acited 2 :e#ruar% 2008B"
http:22wwwanalog-om23ploaded4iles2Data5)heets2'D61!+/5"+/pdf
A2B =e$e7is" =;L20302+E2 8ngu$ar .ate Sensor -ata Sheet" AOn$ine -ocumentB" Acited 2
:e#ruar% 2008B"
http:22wwwmele7is-om2prodfiles2+++5+855#168+9+8%"5we$5datasheetpdf
A*B :airchi$d Semiconductor" >.:*20, 0oer =OS:ET -ata Sheet" AOn$ine -ocumentB"
Acited 2 :e#ruar% 2008B" http:22wwwfair-hildsemi-om2ds2H*2H*4/"+5pdf
A4B /ntersi$" >/040818 809 >igh :re6uenc% >+@ridge -ri(er" AOn$ine -ocumentB" Acited 2
:e#ruar% 2008B" http:22wwwintersil-om2data2an2an80+5pdf
A,B 8tme$" 8Tmega*2 -atasheet" AOn$ine -ocumentB" Acited 2 :e#ruar% 2008B"
http:22wwwatmel-om2dyn2resour-es2prod5do-uments2do-"5+/pdf
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ECE 477 Digital Systems Senior Design Project Spring 2008
'ppendi7 ': )ystem :lo-k Diagram
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